U.S. patent number RE40,681 [Application Number 11/129,760] was granted by the patent office on 2009-03-24 for combination rechargeable, detachable battery system and power tool.
This patent grant is currently assigned to Linvatec Corporation. Invention is credited to Charles E. Alexson, James F. Pitzen, Jeffrey D. Smith.
United States Patent |
RE40,681 |
Pitzen , et al. |
March 24, 2009 |
Combination rechargeable, detachable battery system and power
tool
Abstract
.[.A cordless drive assembly for driving various orthopedic
surgical instruments is described. The drive assembly is battery
powered and includes tracks in the handle portion of its housing
for receiving the battery. A latch locks the battery to the
housing..]. .Iadd.A combination of a rechargeable, detachable
battery system and a power tool. The battery slides onto the power
tool through a complementary groove and flange structure.
.Iaddend.
Inventors: |
Pitzen; James F. (Maplewood,
MN), Smith; Jeffrey D. (Marine on Saint Croix, MN),
Alexson; Charles E. (Hayward, WI) |
Assignee: |
Linvatec Corporation (Largo,
FL)
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Family
ID: |
22980132 |
Appl.
No.: |
11/129,760 |
Filed: |
May 16, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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09954526 |
Mar 5, 2001 |
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09637339 |
Aug 11, 2000 |
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08258338 |
Sep 10, 1996 |
5553675 |
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Reissue of: |
08692886 |
Jul 24, 1996 |
05792573 |
Aug 11, 1998 |
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Current U.S.
Class: |
429/97; 429/100;
429/98; 429/99 |
Current CPC
Class: |
A61B
17/1628 (20130101); B25F 5/02 (20130101); H02K
7/116 (20130101); H02K 7/145 (20130101); H02K
11/0094 (20130101); H02K 11/215 (20160101); H02K
11/33 (20160101); A61B 17/1697 (20130101) |
Current International
Class: |
H01M
2/10 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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3 317 398 |
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Oct 1985 |
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DE |
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3317398 |
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Oct 1985 |
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DE |
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93 19 361 |
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Mar 1994 |
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DE |
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9319361 |
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Mar 1994 |
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DE |
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0 272 434 |
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Jun 1988 |
|
EP |
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0272434 |
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Jun 1988 |
|
EP |
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Other References
Japanese Abstract, 1484694, Portable Drills, Aug. 27, 1974. (1
Page). cited by examiner .
Product brochure entitled "Maxion.TM. Cordless Powered Instrument
System", by 3M HealthCare, (31 pages). (No date). cited by examiner
.
Product brochure entitled: "The K-100 Mini-Driver System. Cleaning
and Lubrication", by 3M Surgical Products Division (5 pages). (No
Date). cited by examiner .
Product brochure entitled: "Cordless 800 Wire Driver", by Dyonics,
1984, (2 pages) (No month). cited by examiner .
Product brochure entitled: "Cordless 200 Reamer" by Dyonics, 1984.
(2 pages). (No month). cited by examiner .
Product brochure entitled "Cordless 450 Orthopedic Drill", by
Dyonics. 1984. (2 pages) (No month). cited by examiner .
Product brochure entitled: "Mini-Driver Air Instrument System" by
3M, 1975. (4 pages) (No month). cited by examiner .
Product brochure entitled: "Acculan" by Aesculap. (4 pages) (No
Date). cited by examiner .
Product brochure entitled: "Cordless Sagittal Saw" by Dyonics.
1984. (2 pages) (No month). cited by examiner .
Product brochure entitled: "The Only Cordless Instrument Powerful
Enough to be Stryker", by Stryker ( 4pages) (No date). cited by
examiner .
Product brochure entitled: "System 2000 Battery Powered
Instruments" by Stryker. 1993 (18 pages) (No month). cited by
examiner .
Product brochure entitled: "System 2000 Battery Powered
Instruments" by Stryker (11 pages) (No date). cited by examiner
.
Instruction Manual entitled: "The Hall Orthair System", by Zimmer
USA. (12 pages) (No date). cited by examiner .
Product brochure entitled: "Maxion Cordless Powered Instrument
System, Assembly, Operation and Maintenance", by 3M HealthCare (6
pages) (No date). cited by examiner .
Hall Versipower Dual Power Orthopedic Instruments. by Zimmer. 1989
(6 pages) (No month). cited by examiner .
Product Insert entitled "Mark III Electric Tool" by Avery Dennison.
(1 page) (No date). cited by examiner .
Operating Instructions entitled, "Mark III Electric Tool", by Avery
Dennison, (12 pages) (No Date). cited by examiner .
Japanese Abstract, 1484694, Portable Drills, Aug. 27, 1974, 1 page.
cited by other .
Sony Overseas S.A., DM/011 603 of Aug. 29, 1988, International
Design Bulletin, Aug. 1988. cited by other .
Sony Overseas S.A. DM/029 376 of Apr. 20, 1994, International
Design Bulletin, Apr. 1994. cited by other .
Product Brochure entitled "Maxion.TM. Cordless Powered Instrument
System Assembly, Operation and Maintence," by 3M HealthCare, 31
pages, no date. cited by other .
Product Brochure entitled "The K-100 Mini-Driver System, Cleaning
and Lubrication," by 3M Surgical Products Division, 5 pages, no
date. cited by other .
Product Brochure entitled "Cordless 800 Wire Driver," by Dyonics,
1984, 2 pages, no month. cited by other .
Product Brochure entitled "Cordless 450 Orthapaedic Drill," by
Dyonics, 1984, 2 pages, no month. cited by other .
Product Brochure entitled "Mini-Driver.TM. Air Instrument System,"
by 3M, 1975, 4 pages, no month. cited by other .
Product Brochure entitled "Acculan," by Aesculap.RTM., 4 pages, no
date. cited by other .
Product Brochure entitled "Cordless Sagittal Saw," by Dyonics,
1984, 2 pages, no month. cited by other .
Product Brochure entitled "The Only Cordless Instrument Powerful
Enough to be Stryker," by Stryker.RTM., 1993, 4 pages, no month.
cited by other .
Product Brochure entitled "System 2000 Heavy Duty Battery Powered
Instruments," by Stryker.RTM., 12 pages, no date. cited by other
.
Instruction manual entitled "The Hall.RTM. Orthair.TM. System," by
Zimmer USA, 12 pages, no date. cited by other .
Product Brochure entitled "Maxion.TM. Cordless Powered Instrument
System, Assembly, Operation and Maintenance," by 3M HealthCare, 6
pages, no date. cited by other .
Product Brochure entitled "Hall.RTM. Versipower.TM. Dual Power
Orthopaedic Instruments," by Zimmer, 1989, 6 pages, no month. cited
by other .
Product insert entitled "Mark III Electric Tool," by Avery
Dennison, 1 page, no date. cited by other .
Operating instructions entitled "Mark III Electric Tool," by Avery
Dennison, 12 pages, no date. cited by other .
Product Brochure entitled "The Air Driver II from 3M," by 3M, 2
pages, no date. cited by other .
Product Brochure entitled "Powered Instrumentation for Large Bone
Surgery," by Stryker.RTM., 16 pages, no date. cited by other .
Product Brochure entitled "Sagittal Saw Attachment," by 3M, 2
pages, no date. cited by other .
Product Brochure entltled "Cordless 200 Reamer," by Dyonics, 1984,
2 pages, no month. cited by other .
Product Brochure entitled "System II OrthoPower 90 Battery Powered
Surgical Instruments," by Stryker.RTM., 1986, 16 pages, no month.
cited by other .
Maintenance manual and operating instructions entitled "System 2000
Battery Powered Instruments," by Styker.RTM., 1993, 17 pages, no
month. cited by other.
|
Primary Examiner: Maples; John S
Attorney, Agent or Firm: Hunton & Williams LLP
Parent Case Text
.[.This application is.]. .Iadd.This reissue patent application is
a continuation of U.S. reissue patent application Ser. No.
09/954,526, filed Mar. 5, 2001, which is a continuation of U.S.
reissue patent application Ser. No. 09/637,339, filed Aug. 11,
2000, now abandoned, which is an application for reissue of U.S.
patent application Ser. No. 08/692,886, filed Jul. 24, 1996, now
U.S. Pat. No. 5,792,573, issued Aug. 11, 1998, which application
.Iaddend.is a divisional of U.S. patent application Ser. No.
08/258,338, filed Jun. 10, 1994, now U.S. Pat. No. 5,553,675,
issued Sep. 10, 1996.
.Iadd.Notice: More than one reissue application has been filed for
the reissue of U.S. Pat. No. 5,792,573. The reissue applications
are: U.S. Reissue application Ser. No. 11/129,760 filed May 16,
2005 (the present application), which is a continuation of U.S.
Reissue application Ser. No. 09/954,526 filed Mar. 5,
2001(pending), which is a continuation of U.S. Reissue application
Ser. No. 09/637,339 filed Aug. 11, 2000(now abandoned). .Iaddend.
Claims
What is claimed is:
.[.1. A rechargeable battery adapted to be repeatably and
releasably attached to an orthopedic drive assembly, the orthopedic
drive assembly having elongate drive and handle portions, a battery
receiving portion having a pair of tracks defining flanges, a pair
of battery terminals, and a blocking member movable between latched
and release positions; said battery comprising: an autoclavable
battery housing having top and bottom portions, at least one cell
within the battery housing and a pair of battery contacts adjacent
the top portion of the housing and situated to engage the battery
terminals of the orthopedic drive assembly, releasable attachment
means for releasably attaching the battery to the battery receiving
portion in a direction other than the direction of elongation of
the handle portion, said releasable attachment means comprising: a)
the battery having a pair of grooves adapted to receive the flanges
of the tracks, and b) a slot for receiving the blocking member when
the blocking member is in the latched position..].
.[.2. A rechargeable battery according to claim 1 wherein each of
the battery terminals comprise a substantially flat plate member
having opposite side surfaces, and each of said battery contacts
comprise a pair of flexible, resilient arcuate members which are
adapted to engage opposite side surfaces of a battery
terminal..].
.[.3. A rechargeable battery according to claim 1 wherein said
battery contacts each include a first end fixedly attached to said
top portion of said battery housing and a second end adapted to
abut a support shoulder of the top portion of the battery
housing..].
.[.4. A rechargeable battery according to claim 1 wherein said
battery housing comprises opposite, substantially flat front and
rear walls constructed from a material suitable for protecting the
cell(s) during an autoclave procedure, said battery comprises eight
substantially cylindrical cells having longitudinal axes, said
eight cylindrical cells being arranged in: a) a front row of three
cells substantially adjacent said front wall within the battery
housing, b) a rear row of three cells substantially adjacent said
rear wall within the battery housing, and c) a middle row of two
cells between said front and rear rows wherein all eight cells are
within the battery housing..].
.[.5. A rechargeable battery according to claim 1 wherein the slot
is sized and shaped to engage the blocking member to lock the
battery to the battery receiving portion when the blocking member
is in the latched position..].
.[.6. A rechargeable battery according to claim 1 wherein the
battery further includes means for automatically moving the
blocking member from the latched toward the release position as the
battery is mounted to the battery receiving portion..].
.[.7. A rechargeable battery according to claim 6 wherein the means
for automatically moving the blocking member comprises a ramped
surface on the top portion of the battery housing..].
.[.8. A rechargeable battery adapted to be repeatably and
releasably attached to an orthopedic drive assembly, the orthopedic
drive assembly having elongate drive and handle portions, a battery
receiving portion having a pair of tracks defining flanges, a pair
of battery terminals, and a blocking member movable between latched
and release positions; said battery comprising a battery housing
having top and bottom portions, at least one cell within the
battery housing, and a pair of battery contacts adjacent the top
portion of the housing and situated to engage the battery terminals
of the orthopedic drive assembly when the battery is fully received
by the orthopedic drive assembly, releasable attachment means for
releasably attaching the battery to the battery receiving portion,
said releasable attachment means comprising: a) the battery having
a pair of grooves adapted to receive the flanges of the tracks, and
b) a slot for receiving the blocking member when the blocking
member is in the latched position, wherein the slot is sized and
shaped to engage the blocking member to lock the battery to the
battery receiving portion when the blocking member is in the
latched position..].
.[.9. A rechargeable battery according to claim 8 wherein the
battery further includes means for automatically moving the
blocking member from the latched toward the release position as the
battery is mounted to the battery receiving portion..].
.[.10. A rechargeable battery according to claim 9 wherein the
means for automatically moving the blocking member comprises a
ramped surface on the top portion of the battery housing..].
.[.11. A rechargeable battery according to claim 8 wherein each of
the battery terminals comprise a substantially flat plate member
having opposite side surfaces, and each of said battery contacts
comprise a pair of flexible, resilient arcuate members which are
adapted to engage opposite side surfaces of a battery
terminal..].
.[.12. A rechargeable battery according to claim 8 wherein said
battery contacts each include a first end fixedly attached to said
top portion of said battery housing and a second end adapted to
abut a support shoulder of the top portion of the battery
housing..].
.Iadd.13. A powered device with a detachable, rechargeable battery
comprising: a housing having an electric motor associated
therewith, an elongate handgrip portion, and a battery receiving
portion attached to a bottom end of the handgrip portion, the
battery receiving portion including battery terminals, the battery
terminals being electrically connected to the electric motor via a
power switch for delivering electric power to the electric motor; a
battery comprising a battery casing, at least one rechargeable
battery cell housed inside of the battery casing, and battery
contacts adapted to contact the battery terminals formed on the
housing when the battery is attached to the housing, the at least
one rechargeable battery cell being electrically connected to the
battery contacts; and wherein one of the housing or the battery
casings has a pair of flange formed thereon, and the other of the
housing or the battery casing has a pair of mounting grooves formed
thereon which engage the pair of flanges in a direction of
engagement other than the general direction of elongation of the
handgrip portion when the rechargeable battery is mounted to the
housing; and wherein the handgrip portion does not house any part
of the electric motor. .Iaddend.
.Iadd.14. The tool of claim 13 wherein a drill chuck is operatively
connected to the electric motor to drive a drill. .Iaddend.
.Iadd.15. The tool of claim 13 further comprising means for
releasably securing the battery to the battery receiving portion.
.Iaddend.
.Iadd.16. The tool of claim 13 wherein the rechargeable battery
cell comprises at least two electrically connected, individual,
rechargeable, cylindrical battery cells arranged in a plurality of
rows and housed inside of the battery casing. .Iaddend.
.Iadd.17. The tool of claim 13 wherein the pair of flanges or the
pair of mounting grooves that is formed on the battery casing is at
least one-third the length of a top portion of the battery casing.
.Iaddend.
.Iadd.18. The tool of claim 13 wherein the rechargeable battery
cell comprises at least five series electrically connected,
individual, rechargeable, cylindrical battery cells arranged in a
plurality of rows and housed inside of the battery casing; and the
pair of flanges or the pair of mounting grooves that is formed on
the battery casing is at least one-third the length of a top
portion of the battery casing. .Iaddend.
.Iadd.19. The tool of claim 16 wherein the battery casing comprises
two halves joined together, and each of the halves formed
approximately a half of a top portion of the battery casing and a
half of a bottom portion of the battery casing. .Iaddend.
.Iadd.20. The tool of claim 16 wherein the pair of flanges is a
pair of parallel flanges, and the pair of mounting grooves is a
pair of parallel mounting grooves. .Iaddend.
.Iadd.21. The tool of claim 13 wherein the housing further
comprises a motor portion attached to a top end of the handgrip
portion opposite the handgrip portion's bottom end, and wherein a
longitudinal axis of the handgrip portion intersects the motor
portion and the battery receiving portion and the battery casing
when the battery is attached to the housing. .Iaddend.
.Iadd.22. The tool of claim 21 wherein the rechargeable battery
cell comprises at least five electrically connected, individual,
rechargeable, cylindrical battery cells arranged in a plurality of
rows and housed inside of the battery casing. .Iaddend.
.Iadd.23. The tool of claim 22 wherein the pair of flanges or the
pair of mounting grooves that is formed on the battery casing is
formed on a top portion of the battery casing opposite a bottom
portion with a generally flat bottom surface. .Iaddend.
.Iadd.24. The tool of claim 22 wherein the battery contacts are
positioned on the top portion of the battery casing between the
pair of flanges or the pair of mounting grooves that is formed on
the battery casing. .Iaddend.
.Iadd.25. The tool of claim 13 wherein the battery casing further
comprises a top portion and an opposite bottom portion, the bottom
portion having a substantially flat bottom surface that is parallel
to the direction of engagement, and wherein the pair of flanges or
the pair of mounting grooves that is formed on the battery casing
is formed on the top portion of the battery casing. .Iaddend.
.Iadd.26. The tool of claim 25 wherein the battery contacts are
positioned between the pair of flanges or the pair of mounting
grooves that is formed on the battery casing. .Iaddend.
.Iadd.27. The tool of claim 26 wherein the battery contacts and the
battery terminals comprise a substantially flat plate member having
opposite side surfaces, and resilient deflecting members which
engage the opposite side surfaces of the plate member.
.Iaddend.
.Iadd.28. A powered device with a detachable, rechargeable battery
comprising: a housing having an electric motor associated
therewith, an elongate handgrip portion, and a battery receiving
portion attached to a bottom end of the handgrip portion, the
battery receiving portion including battery terminals, the battery
terminals being electrically connected to the electric motor via a
power switch for delivering electric power to the electric motor; a
battery comprising a battery casing, at least one rechargeable
battery cell housed inside of the battery casing, and battery
contacts adapted to contact the battery terminals formed on the
housing when the battery is attached to the housing, the at least
one rechargeable battery cell being electrically connected to the
battery contacts; and a drill chuck operatively connected to the
electric motor to drive a drill; wherein one of the housing or the
battery casing has a pair of flanges formed thereon, and the other
of the housing or the battery casing has a pair of mounting grooves
formed thereon which engage the pair of flanges in a direction of
engagement other than the general direction of elongation of the
handgrip portion when the rechargeable battery is mounted to the
housing. .Iaddend.
.Iadd.29. The tool of claim 28 wherein the electric motor drives a
planetary gear transmission, and the planetary gear transmission
drives a drive spindle adapted to mount the drill chuck.
.Iaddend.
.Iadd.30. The tool of claim 28 wherein the rotary axis of the
electric motor is parallel to the direction of engagement.
.Iaddend.
.Iadd.31. The tool of claim 28 wherein the rechargeable battery
cell comprises at least five electrically connected, individual,
rechargeable, cylindrical battery cells arranged in a plurality of
rows in a single plane and housed inside of the battery casing.
.Iaddend.
.Iadd.32. The tool of claim 31 wherein the longitudinal axes of all
of the battery cells are parallel to each other and perpendicular
to the single plane. .Iaddend.
.Iadd.33. A powered device with a detachable, rechargeable battery
comprising: a housing having an electric motor associated
therewith, an elongate handgrip portion, and a battery receiving
portion attached to a bottom end of the handgrip portion, the
battery receiving portion including battery terminals, the battery
terminals being electrically connected to the electric motor via a
power switch for delivering electric power to the electric motor;
and a battery comprising a battery casing, at least five
electrically connected, individual, rechargeable, cylindrical
battery cells arranged in a plurality of rows in a single plane and
housed inside of the battery casing, and battery contacts adapted
to contact the battery terminals formed on the housing when the
battery is attached to the housing, the battery cells being
electrically connected to the battery contacts; wherein one of the
housing or the battery casing has a pair of flanges formed thereon,
and the other of the housing or the battery casing has a pair of
mounting grooves formed thereon which engage the pair of flanges
when the rechargeable battery is mounted to the housing.
.Iaddend.
.Iadd.34. The tool of claim 33 wherein a drill chuck is operatively
connected to the electric motor to drive a drill. .Iaddend.
.Iadd.35. The tool of claim 33 further comprising a saw blade
mounted for reciprocating motion and driven by the electric motor.
.Iaddend.
.Iadd.36. The tool of claim 33 wherein the pair of flanges is a
pair of parallel flanges, and the pair of mounting grooves is a
pair of parallel mounting grooves. .Iaddend.
Description
TECHNICAL FIELD
The present invention is directed to cordless rechargeable battery
powered drive assemblies for driving orthopedic surgical
instruments.
BACKGROUND
Orthopedic drive assemblies are well known in the art. Such drive
assemblies may be adapted for various orthopedic procedures such as
drilling, screwing, reaming, wire driving, pinning and sawing (both
reciprocating and sagittal). Typically a drive assembly is powered
by either a rechargeable battery system (e.g. a cordless system) or
by a pneumatic system which utilizes compressed fluid to power the
device.
The art is replete with cordless rechargeable battery powered drive
assemblies for driving orthopedic surgical instruments. Typically,
such instruments comprise generally pistol-shaped devices having
elongate handle and drive portions. Examples of such drive
assemblies comprise: (1) the Orthopower 90 cordless instruments
available from Stryker of Kalamazoo, Mich.; (2) the Cordless 200
Reamer, Cordless 800 Wire Driver, Cordless Sagittal Saw or Cordless
450 Orthopedic Drill available from Dyonics of Andover Md., (3) the
Maxion.TM. orthopedic drive device, previously sold by the
Minnesota Mining and Manufacturing Co. (3M) of St. Paul, Minnesota;
(4) the Hall Versipower orthopedic instruments available from Hall
Surgical of Carpinerina California (associated with Zimmer); and
(5) the product known as the 200 Reamer, previously sold by Black
& Decker. Cordless battery powered drive assemblies for driving
orthopedic surgical instruments are described in U.S. Pat. Nos.
3,734,207; 4,050,528; 4,091,880; 4,441,563; 4,641,076; 4,728,876
and 5,080,983.
Because the batteries in an orthopedic drive device are preferably
rechargeable, releasable attachment means are provided in some
prior art devices for releasably attaching a battery pack to the
rest of the device. Typically, a battery pack is attached to and
removed from the handle portion of the device in a direction that
is substantially parallel to the axis of elongation of the handle
portion. Individual batteries are placed in a housing creating the
battery pack which is then attached to the device by being slid in
a direction generally parallel to the elongate axis of the handle
portion of the device. The battery pack typically includes
electrical circuit connection means for connecting the battery pack
to electronic circuitry in the device. A device typically secures
the battery pack to the rest of the device.
While such releasable attachment means are generally acceptable,
they leave room for improvement. One drawback of such a releasable
attachment means is that gravity tends to continuously operate on
the battery pack to urge it out of the device. Another drawback for
some prior devices is that, because of the significant vibration
forces encountered during use of the orthopedic drive assembly
(particularly during sagittal sawing), the electrical circuit
connection means tend to corrode. This type of corrosion is known
as fretting corrosion. As used herein, the phrase "fretting
corrosion" means surface degradation occurring at the interface of
mating electrical contacts which results in the reduction or even
loss of electrical continuity.
Fretting corrosion is found in components forming contacts which
are allowed to move independently with respect to each other during
current flow. This independent movement is believed to cause
mechanical abrasion which will wear the surfaces. Gaping between
the electrical contacts during electrical flow may result in
electrical arcing with attendant generated heat potentially
sufficient to melt the surface of the contacts. Pitting, welding
and burning may also result. Also, a physical change in the
material forming the contacts may occur. Plating for enhanced
electrical contact may be lost and carbon deposits may accumulate
resulting in reduced electrical continuity.
Because orthopedic drive assemblies are used in surgical procedures
which require delicate yet physically demanding tasks, the balance
and maneuverability of an orthopedic drive device is also important
to surgeons. Hand fatigue is a problem associated with many
existing drive assemblies as well as a general difficulty in
maneuvering the device during some surgical procedures. Weight
distribution and size considerations are believed to contribute to
these problems, as the typical cordless rechargeable battery
powered drive assembly may be cumbersome to hold and use,
particularly during a delicate orthopedic procedure where only the
height quality is tolerated. Size and weight considerations
involved in the placement of elements such as the batteries,
transmission, electronic control circuitry and motor typically
render an existing device to maneuver.
Other prior art drive assemblies are excessively large. Oversized
drive assemblies may be difficult to maneuver, particularly during
a surgical procedure at a cramped or remote location.
BRIEF DESCRIPTION OF THE INVENTION
According to the present invention there is provided a drive
assembly for driving orthopedic surgical instruments which (1)
affords excellent balance and maneuverability for a user which
offers enhanced handling characteristics and convenience during
use, (2) affords attachment and removal of a battery pack in a
direction other than the direction of elongation of the handle
portion of the device, (3) includes a connection between the
battery pack and the electronic circuitry of the device which
resists fretting corrosion, (4) includes an ergonomically designed
handgrip shape that fits a surgeon's hand comfortably, and (5) is
sized for convenient maneuvering during an orthopedic surgical
procedure.
According to the present invention, there is provided a drive
assembly for driving various orthopedic surgical instruments, such
as, but not limited to, drills, screws, reamers, wires, pins and
saws (both reciprocating and sagittal). The drive assembly
comprises a housing having elongate drive and handle portions with
the handle portion projecting from the drive portion. A drive is
present comprising an motor preferably mounted within the drive
portion. The motor has a motor shaft, and the drive includes a
transmission for transmitting power of the motor shaft to the
surgical instrument. The transmission includes a drive member.
Preferably the drive portion has surfaces defining a wire receiving
chamber adapted to receive an orthopedic wire adapted to be driven
during an orthopedic surgical procedure.
The drive assembly also includes a trigger assembly movable
relative to the handle portion; and electrical circuit means
operatively associated with the trigger assembly for controlling
the motor.
The handle portion comprises a releasably attachable battery having
at least one cell (preferably eight), a battery housing, and a pair
of battery contacts. The handle portion also has a battery
receiving portion having battery terminals adapted to engage the
battery contacts; and releasable attachment means for releasably
attaching the battery to the battery receiving portion in a
direction other than the direction of elongation of the handle
portion. Preferably, the direction is a direction substantially
parallel to the axis of the drive portion.
In the preferred embodiment, the releasable attachment means
comprises a) the handle portion having a pair of tracks defining
flanges that are elongate in a direction substantially parallel to
the longitudinal axis of the drive portion, b) the battery having a
pair of grooves adapted to receive the flanges of the tracks, and a
pair of flexible, resilient cantilever members, and c) the battery
receiving portion having surfaces defining a cantilever member
cavity for receiving the pair of flexible, resilient cantilever
members in an interface fit so that the battery is frictionally
held in place relative to the battery receiving portion. A latch
for releasably securing the battery to the battery receiving
portion is also preferably present.
The drive assembly also includes a novel floating battery terminal
assembly comprising biasing means for biasing the battery terminals
toward a rest position, and mounting means for mounting the battery
terminals for deflection from the rest position. In one embodiment,
each of the battery terminals comprises a substantially flat plate
member having opposite side surfaces, and each of the battery
contacts comprise a pair of flexible, resilient arcuate members
which are adapted to engage opposite side surfaces of a battery
terminal.
Also preferably, the handle portion comprises a handgrip portion
having outer surfaces that are sized and shaped to be grasped by a
user without touching the battery, and inner surfaces defining a
handgrip cavity. The handgrip cavity is free of the transmission,
the motor and any cells of the battery when the battery is received
in the battery receiving portion. Preferably, the cells of the
battery are spaced on an opposite end of the handgrip portion than
the motor and transmission.
Alternatively, the present invention may be described as a
rechargeable battery adapted to be repeatedly and releasably
attached to an orthopedic drive assembly. In this aspect of the
invention, the orthopedic drive assembly has elongate drive and
handle portions, a battery receiving portion having a pair of
tracks defining flanges, a pair of battery terminals, and surfaces
defining a cantilever member receiving cavity.
The battery comprises an autoclave battery housing having opposite
top and bottom portions, at least one cell within the battery
housing and a pair of battery contacts mounted adjacent the top
portion of the housing and adapted to engage the battery terminals
of the orthopedic drive assembly. Releasable attachment means are
present for releasably attaching the battery to the battery
receiving portion in a direction other than the direction of
elongation of the handle portion. The releaseable attachment means
and battery terminals comprise the preferred versions as discussed
above.
In this aspect of the invention, the battery contacts each include
a first end fixedly attached to the top portion of the battery
housing and a second end adapted to abut a support shoulder of the
top portion of the battery housing. The battery housing comprises
opposite, substantially flat front and rear walls constructed from
a material suitable for protecting the cell(s) during an autoclave
procedure. The battery comprises eight substantially cylindrical
cells having longitudinal axes. The eight cylindrical cells are
arranged in: a) a front row of three cells substantially adjacent a
front wall of the battery housing, b) a rear row substantially
adjacent a rear wall of the battery housing, and c) a middle row of
two cells between the front and rear rows.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further described with reference to
the accompanying drawings wherein like reference numerals refer to
like parts in the several views, and wherein:
FIG. 1 is a perspective view of a drive assembly for driving
orthopedic surgical instruments according to the present
invention;
FIG. 2 is an enlarged sectional view of the drive assembly of FIG.
1, illustrating a battery pack of the device removed from the
device in solid lines, and illustrating the position of the battery
pack when attached to the drive assembly in phantom lines;
FIG. 3 is an enlarged perspective view of the battery pack for use
in the drive assembly of FIG. 1;
FIG. 4 is an enlarged rear view of the drive assembly of FIG.
1;
FIG. 5 is a top view of the battery pack of FIG. 3;
FIG. 6 is a sectional view of the battery pack of FIG. 3;
FIG. 6A is a bottom view of portions of the drive assembly of FIG.
2 with the battery pack removed which illustrates battery terminals
that are adapted to be connected to the battery contacts of the
battery pack of FIG. 3;
FIG. 7 is an enlarged side view of the drive assembly of FIG.
1;
FIG. 8 is a top view of the orthopedic drive assembly of FIG.
7;
FIG. 9 is a front view of the drive assembly of FIG. 7;
FIG. 10 is a side view of the battery pack of FIG. 3;
FIG. 11 is an enlarged bottom view of a handle portion of a drive
assembly with the battery pack removed to illustrate details of a
second embodiment of battery terminals according to the present
invention and with portions of a battery pack receiving cavity
illustrated with dashed lines;
FIG. 12 is a partial sectional view of a battery receiving portion
of the drive assembly and cantilever arms of the battery pack
showing the position of the cantilever arms when the battery pack
is attached to the rest of the orthopedic drive assembly;
FIG. 13 is a top view of one of a pair of preferred battery
contacts for a battery pack according to the present invention,
which battery pack is adapted to be connected to a drive assembly
having the battery terminals of FIG. 11;
FIG. 14 is a side view of the battery contact of FIG. 13;
FIG. 15 is an enlarged bottom view of portions of the handle
portion of the drive assembly of FIG. 11 which illustrates details
of a pair of floating battery terminal assemblies including a
battery terminal of one of the assemblies shown offset relative to
the axis of the drive portion of the housing of the device;
FIG. 16 is a sectional view of a floating battery terminal assembly
of FIG. 15 which illustrates details of a battery terminal in a
rest position;
FIG. 17 is a sectional view of portions of the drive assembly of
FIG. 16 taken approximately along lines 17--17 of FIG. 16 except
that one battery terminal and connector are removed to illustrate
details of a hole for receiving the battery terminal;
FIG. 18 is a sectional view similar to FIG. 16 except that the
floating battery terminal assembly is slightly offset from its rest
position, as may occur during vibration of the orthopedic drive
device;
FIG. 19 is a sectional view of the floating battery terminal of
FIG. 17 with the battery terminal offset laterally with respect to
its longitudinal axis in a rest position and with other portions
omitted to illustrate details;
FIG. 20 is a sectional view of the floating battery terminal
assembly of FIG. 17 with the battery terminal illustrated in a rest
position and with other portions omitted to illustrate details;
FIG. 21 is a schematic illustration of a switch mechanism for use
in the drive assembly according to the present invention;
FIG. 22 is a top view of another embodiment of battery contact for
use with a drive assembly having the battery terminals of FIG.
11;
FIG. 23 is a side view of the battery contact of FIG. 22; and
FIG. 24 is a perspective view of a battery with the battery
contacts of FIGS. 13 and 14.
DETAILED DESCRIPTION
Referring now to FIGS. 1 through 10 of the drawing there is shown
an embodiment of a cordless rechargeable battery powered drive
assembly for driving orthopedic surgical instruments according to
the present invention, generally designated by reference character
10. The drive assembly 10 includes a housing comprising elongate
drive 4 and handle 6 portions defining drive D and handle H portion
longitudinal axes. The drive portion 4 and a significant portion of
the handle portion 6 are constructed by assembling two large
housing pieces (see FIG. 7) to afford convenient disassembly of the
device for repair.
Referring now to FIG. 2, the drive assembly 10 includes a motor
assembly having a D.C. electric powered motor 12 including a rotor
14 and a motor shaft 16. A drive is also present comprising a
transmission for transmitting the power of the motor shaft 16 to
the surgical instrument. The illustrated transmission includes a
drive member or spindle 18, a ring gear 19, and a gear pin and
planetary gear assembly 21.
Preferably, the motor 12 is mounted within the drive portion 4. As
used in this application, when it is said that the motor is within
the drive portion 4, it is meant that the rotor 14 and motor shaft
16 are substantially completely located within the structure of the
housing defining the drive portion 4, as opposed, for example, to
one of the rotor or motor shaft being located in the handle portion
6 or a substantial portion of the motor being located in the handle
portion 6, of course some wires and electronic circuitry associated
with the motor may be present outside the drive portion 4, and yet
the motor will nevertheless be within the drive portion 4 as
understood in the present invention. Also preferably, the
transmission (e.g. 18, 19 and 21) is mounted within the drive
portion 4.
A connector is provided for attaching a chuck or other such holder
or instrument that may be driven by the drive assembly 10. The
connector comprises a nose insert 26 having a socket into which a
cylindrical portion of the surgical instrument can project with a
splined central rotatable driven collar engaged with mating splines
17 on the inner surface of the drive member 18, and with pins (not
shown) projecting radially of the cylindrical portion engaged in
longitudinally extending slots 15 opening through the end of the
housing. A helix pin/collar assembly 25 is rotatable about the axis
D of the drive portion and is biased by torsion spring 27 so that
circumferentially projecting hooks near slots 15 on the collar 25
can engage the pins on the surgical instrument to maintain the pins
within the slots 15 and thereby the surgical instrument in driven
engagement with the drive assembly 10.
The surgical instrument may comprise any instrument suitable for
use in an orthopedic surgical procedure, including but not limited
to, drills, screws, reamers, pins and saws (both reciprocating and
sagittal) or a suitably designed chuck or adapter for use with any
of the previously mentioned instruments.
As a particular example, the surgical instrument may comprise the
chuck described in U.S. Pat. No. 4,728,876, the entire contents of
which are herein expressly incorporated by reference.
Alternatively, for example, an appropriate wire driving attachment
adapter may be attached to the drive assembly 10 so that it may be
used as an orthopedic wire driver, optionally, but not preferably,
engagement between the orthopedic wire and the spindle 18 may
afford operation of the device 10 as a wire driver.
A stationary member 22 extends from a proximal end 1 of the housing
toward its distal end 3. Preferably, the stationary member 22
includes a through chamber so that a surgical wire may be passed
through the stationary member 22 from the proximal end 1 of the
device 10 toward the distal end 3. The through chamber in the
stationary member 22 forms a portion of a wire receiving chamber in
the drive portion 4 between the proximal end 1 and the distal end
3. Threading a surgical wire through the wire receiving chamber
affords use of the device 10 as a wire driver.
O-rings 64 and 65 restrict internal contamination of the drive
assembly 10 from ambient contaminants. O-ring 66 is compressed
against member 22 to restrict the member 22 from rotating relative
to the handle 6 and drive 4 portions of the housing.
The drive assembly 10 also includes a rechargeable battery or
battery pack 30 that is adapted to provide a rechargeable source of
power for the motor 12. Unique mounting means (described in greater
detail below) attach the battery 30 to the rest of the assembly
10.
A trigger assembly 40 is movable relative to the handle portion 6.
The trigger assembly includes a button member 45 adapted to be
engaged by a user's digits, a trigger shaft 46, an O-ring seat 41
for fixedly connecting the button member 45 to the trigger shaft
46, a coil spring 42 and magnet 44 that is rigidly attached to the
trigger shaft 46. The trigger assembly 40 is movable between a
released or extended position (FIG. 2) and a depressed or inner
position relative to the handle portion 6.
The drive assembly 10 also includes electrical circuit means
operatively associated with the trigger assembly 40 for controlling
the motor 12. The illustrated electrical circuit means comprises an
on/off hall sensor 52 and a speed control hall sensor 54.
The on/off hall sensor 52 is a digital hall sensor having an output
signal with two levels corresponding to an on state and an off
state. The on/off hall sensor 52 senses the presence of a magnetic
field from the magnet 44 on the trigger assembly 40. When the
trigger assembly 40 is released, the magnet 44 is positioned
directly over the on/off hall sensor 52 (FIG. 2). The magnetic
field of the magnet 44 causes the on/off hall sensor 52 to produce
an output signal corresponding to an off state. As the trigger
assembly 40 is depressed, the magnet 44 moves away from the on/off
hall sensor 52. The on/off hall sensor 52, no longer sensing the
presence of a magnetic field, produces an output signal
corresponding to an on state.
The output signal from the on/off hall sensor 52 is conditioned by
electrical circuitry which provides a standby signal when the
on/off hall sensor 52 produces an off signal. The standby signal
disables motor drive circuitry and the speed control hall sensor
54. The standby signal therefore ensures that the motor 12 is off
whenever the trigger assembly 40 is in a released position (FIG.
2). An added benefit of disabling the motor drive circuitry and the
speed control hall sensor 54 is that the electrical power required
by the device 10 is significantly reduced during periods when the
trigger assembly 40 is not depressed. This current reduction during
a standby mode improves energy efficiency of the device 10. In this
manner, the device 10 may optionally include a battery saver
feature.
The speed control hall sensor 54 is a linear ball sensor which
provides a speed control signal having a range of levels based upon
the strength of the magnetic field that the variable speed hall
sensor 54 detects. As the strength of the magnetic field increases,
the speed control hall sensor 54 produces a speed control signal
with a higher level. As the trigger assembly 40 is depressed, the
magnet 44 moves towards the speed control hall sensor 54 and
increases the magnetic field across it. The speed control signal
from the speed control hall sensor 54 is conditioned and drives the
motor control circuit to provide motor speeds proportional to the
speed control signal. Therefore, as the trigger assembly 40 is
further depressed, the motor control circuitry increases the motor
speed of the drive assembly 10. In this manner, the drive assembly
10 may optionally comprise a variable speed device.
The circuit has a 25 amp current limit to protect the batteries,
motor and electronics. The electrical circuit means may optionally
include directional drive circuitry which is discussed in greater
detail below.
As best seen in FIGS. 2 and 6A, the device 10 also comprises
battery terminals 39. Each of the battery terminals 39 have three
generally flat surfaces including two end surfaces situated at an
angle relative to a middle surface. The function of the battery
terminals 39 will be described in greater detail below.
The battery terminals 39 may be constructed from any suitable
material appropriate for use to construct orthopedic surgical
tools. For example, the battery terminals may be constructed from
copper, brass, bronze, beryllium copper, stainless steel, steel and
aluminum. One or more platings may be present to enhance the
electrical conducting and corrosion resisting properties of the
battery terminals 39. Examples of such platings include, but are
not limited to copper, nickel, gold, silver, tin, electroless
nickel, rhodium, sulfamate, nickel, cadmium and zinc.
The handle portion 6 of the device 10 projects (downwardly in FIG.
2) from the drive portion 4 of the device 10. The handle portion 6
of the housing comprises the battery 30 and a handgrip portion 5.
The handgrip portion 5 has manually engageable or graspable
surfaces and top T and bottom B ends (see FIG. 2). Preferably, the
handgrip portion 5 is sized and shaped so that, during use of the
device 10, the user does not need to grasp any portion of the
battery 30. For example, the handgrip portion 5 may have a height
from its bottommost point to the bottom of the drive portion 4 of
less than approximately 6 inches (preferably about 4.5 inches), a
width of its neck portion of less than about 2.8 inches (preferably
about 1.1 inches), and a length of its neck portion of less than
about 2.5 inches (preferably about 1.3 inches).
The handgrip portion 5 includes specially shaped surfaces that
result in a handle that is comfortably held in the head of a
surgeon. A middle part of the handgrip 5 includes an curved front
surfaces to form a conveniently held handle. A lip portion 51 is
situated adjacent the button member 45 to restrict the chance that
a surgeon's glove may be caught between the handle portion 6 and
the button 45 when the button 45 is depressed.
As shown in the figures, the width and length of the handgrip
portion 5 vary along its height to afford convenient grasping of
the device 10. The bottom of the handgrip portion 5 includes a
battery receiving portion 48 having the battery terminals 39
adapted to engage battery contacts 33 (described in greater detail
below) when the battery 30 is attached to the battery receiving
portion 48.
A battery housing 31 (FIGS. 2 and 3) preferably comprises opposite,
substantially flat front 201 and rear 203 walls constructed from an
autoclavable material. An autoclavable material is a material
suitable for protecting battery cell(s) during repeated autoclave
procedures. Examples of suitable materials are described below.
The battery 30 comprises at least one rechargeable cell 32 and
preferably eight substantially cylindrical cells 32 as shown in
FIG. 2. Because the cells 33 are located in a position below or
remote from where a user is expected to grasp the drive assembly
10, the handgrip portion is free to be used for mounting other
electrical and/or mechanical components such as an electronic
printed circuit board forming a portion of the electrical circuit
means discussed above.
The battery 30 preferably comprises eight substantially cylindrical
cells 32 having longitudinal axes. The axes of the cells are
preferably substantially parallel to the front and rear walls 201
and 203. The eight cylindrical cells 32 are arranged in a front row
F of three cells substantially adjacent the front wall 201, a rear
row R of three cells substantially adjacent the rear wall 203, and
a middle row M of two cells between the front and rear rows 201 and
203. All of the rows F, M and R are enclosed within the battery
housing 31 so that the cells are protected during an autoclave or
other sterilization procedure.
The weight distribution of the device 10 is substantially balanced
about the handgrip portion 5 as the relatively heavier elements
such as the battery cells and the motor/transmission assemblies of
the device 10 are spaced on opposite ends (top T and bottom B) of
the handgrip 5. A handgrip cavity 53 is formed within the inner
portions the handgrip 5. As opposed to prior art devices which
include a battery or motor within the portion of its housing that
is designed to be manually grasped, the cavity 53 is free of
batteries or motors or transmission or gear assemblies. Since
battery cells 30 (described in greater detail below) are situated
below the battery receiving portion of the handle portion 6, some
of the electronic control circuitry mentioned above may be placed
in the handgrip cavity 53 of the handle portion 6. This is believed
to further contribute to the beneficial balance and handling
characteristics of the device 10.
The cells 32 are preferably stacked in the manner shown in FIG. 2,
with a distal row of three cells placed at the front of the battery
30, a proximal row three cells at the rear of the battery 30, and a
middle row of two cells placed between the front and rear cells.
The axes of the cells are perpendicular to the axis D of the drive
portion of the housing. The cells 32 may comprise, for example,
nickel-cadmium secondary (rechargeable) sub "C" size cells with a
22 mm diameter and a 34 mm length in a nickel-plated steel case.
Such cells are expected to provide a capacity of about 1.4 amp
hours at 9.6 volts, D.C. Suitable cells may be obtained from Saft
of Valdosta. Ga.; Panasonic of Japan; Sanyo Electric Co. Ltd. of
Sumoto-City, Hyogo Japan or Gates available from DC Battery
Products of St. Paul, Minn.
The cells 32 are enclosed in an autoclave proof (saturated stream @
280 degrees Fahrenheit, @ 30 pounds per square inch, and vacuum @
26 inches of mercury) housing or casing 31. The casing 31
preferably is designed to withstand other sterilization techniques
and remain suitable to protect the battery cells 32. The casing 31
includes a poppet or umbrella valve 8 (e.g. the #VL2491-102 Vernay
valve generally available from Vernay of Calif.) to relieve any
pressure, such as pressure generated by the cells 32. Optionally,
the battery housing 31 may include a power terminal (not shown) for
a power cord so that the drive assembly 10 may be powered without
discharging the cells 32.
The particular material used to construct the casing 31 may
comprise any suitable material for use in an orthopedic device.
Specific examples include, but are not limited to, poly-ether-imide
(PET) including Ultem (e.g. GE grades 1000 Black #7101, 1000 Black
#1000, 2100 muddled natural #1000 10% glass fill, 2200 muddled
natural 20% glass fill, 3452 muddled natural #1000 45% short glass
and mineral, or 6200 muddled natural #1000 20% glass fill high
temperature); poly-phenyl-sul-fone (PPSU) (e.g. Amoco Radel R,
grades R5100 Black #935 or #937, or R 5000, natural); polysulfone
(PSU) (e.g. Amoco Udel P, grade P 1700, natural #11);
polyaryletherketone (PAEK) (e.g. BASF Ultrapek, grade KR4176,
natural); liquid crystal polymer (LCP) (e.g. Vectra grades A950
natural, A530 muddled natural moderately mineral filled, or A130
muddled natural 30% glass fill); and polyketone (PEK) (e.g. Amoco
Kadel E grade 1000 natural).
The motor 12 of the drive assembly 10 is designed to: (1) operate
between about 9.6 volts and a reduced voltage which is the output
range the battery will produce under load, and (2) have very low
internal resistance to restrict internal losses when handling the
high current flow by which it is powered. Since the motor 12 and
transmission are relatively heavy elements of the device 10 (e.g.
the motor may weight about 0.82 pounds), the motor 12 and
transmission are preferably located within the drive portion 4 of
the housing. Locating the motor 12 and transmission in a position
spaced from the handgrip cavity 53 frees the handgrip cavity 53 for
use to store the electronic circuitry of the device 10. The
location of the motor 12 and transmission also contribute to the
beneficial balance and weight distribution of the device 10 and
improves its handling characteristics. These improvements are
believed to reduce hand fatigue for some users.
The battery 30 shown in FIGS. 1-7, 9 and 10 comprises the battery
housing or casing 31, and a pair of battery contacts 33, one of
which is an electrically positive terminal, the other of which is
an electrically negative terminal. The battery contacts 33 comprise
thin, arcuate contact members. The arcuate contact members 33 are
connected at one end to the housing 31 and are in electrical
communication with the cells 32 (which are connected in series by
electrically conductive strips). The other end of the contact
members 33 is free to float along the top of the casing 31.
Preferably, the contacts 33 are constructed from a flexible,
resilient electrically conductive material, such as a material
selected from the group comprising copper, brass, bronze, beryllium
copper, nickel, stainless steel, aluminum or steel. Optionally, one
or more materials may be plated to the contacts to enhance their
performance and corrosion resistance. Plating materials include,
but are not limited to gold, copper, nickel, silver, tin
electroless nickel rhodium, sulfamate nickel, cadmium and/or zinc.
The shape of the arcuate contact/members 33 afford their resilient
deflection in a direction substantially parallel to the axis H of
the handle portion 6 of the housing upon abutment with the battery
terminals 39.
Referring now to FIGS. 11, 13-14, 15-16, 18-20 and 24 of the
drawings, there is shown a second embodiment of cooperable battery
terminals and battery contacts according to the present invention
with the battery contacts designated with reference character 33A
and the battery terminals designated by reference character
39A.
As best seen in FIG. 16, handgrip 5 has a portion constructed from
an electrically insulating material 106. The battery terminals 39A
are each attached to the insulating material 106 by screw 87. A
crimp-on connector 107 is situated between the screw 87 and the
battery terminal 39A. The crimp-on connector 107 places the battery
terminal 39A in electrical communication with the rest of the
electrical circuit means by virtue of insulated wire 108.
The battery terminals 39A are mounted on the manually graspable
portion 5 of the housing to float relative to the rest of the
housing (including the insulating portion 106). This feature is
particularly useful when the device 10 generates vibration as the
floating battery terminals 39A tend to retain electrical
communication between the battery 30 and the rest of the
electronics of the device 10.
The battery terminal 39A is placed in an oblong hole 88 in the
handgrip portion 5 of the housing. The oblong hole 88 preferably
affords side to side float (movement in a direction that is
substantially perpendicular to both axes H and D) of the battery
terminal 39A (see FIG. 19), but restricts float of the battery
terminal 39A in a direction substantially parallel to the axis D so
that the battery terminal 39A is not unduly deflected upon
insertion and removal of the battery 30 from the device 10.
A coil spring 89 is provided to afford float of the battery
terminal 39A and to bias the battery terminal 39A toward a rest
position (see FIGS. 16 and 20). The coil spring 89 has a pair of
ends, one of which abuts the crimp-on connector 107, and the other
of which abuts the insulating portion 106 of the housing. A rest
position of battery terminals 39A is shown in FIG. 16. When the
battery terminal 39A is deflected from its rest position (such as
when the device 10 vibrates during an orthopedic surgical
procedure), the spring 89 deflects in compression from its rest
position and biases the battery terminal 39 toward its rest
position. Alternatively, the spring 89 may be designed to deflect
in tension from its rest position to bias the battery terminal 39
toward its rest position.
The screw 87, crimp-on connector 107, coil spring 89 and portions
of the battery terminals 39A are situated within cavity 109 in the
handgrip 5. The cavity 109 has a diameter at least slightly larger
than the diameter of the screws 87 to afford float of the battery
terminals 39A. Unlike the battery terminals 39A, the battery
terminals 39A comprise a substantially flat, rectangular contact
member having a pair of opposite sides 91 and 92 for contacting the
battery contacts 33A.
Battery contacts 33A for use with the battery terminals 39A is
shown in FIGS. 13, 14 and 24. Each of the battery contacts 33A
include a pair of flexible, resilient deflecting members 81 and 82.
The flexible, resilient deflecting members 81 and 82 each have a
first end rigidly affixed to the battery housing 31, and a second
end, opposite the first end. The second end of the members 81 and
82 is free to slide along the top of the casing 31 when the members
81 and 82 are deflected. A support shoulder surface 115 of the top
portion of the battery housing 31 receives the second end of the
members 81 and 82 and affords sliding movement of the second ends
of the members 81 and 82.
The battery terminal 39A is designed to be sandwiched between the
flexible, resilient deflecting members 81 and 82 and to deflect the
members 81 and 82 in a direction that is substantially
perpendicular to both of the axes H and D during vibration of the
battery terminals 39A. Preferably, side 91 of the battery contact
33A is in electrical communication with deflecting member 81, and
side 92 of the battery contact is in electrical communication with
deflecting member 82.
The battery contacts 33A are constructed from a flexible,
resilient, electrically conductive material. Any of the materials
and platings mentioned above for use in constructing the battery
contacts 33 may be used to construct the battery contacts 33A.
Particular examples include beryllium copper, Brush Wellman alloy
25, 0.0159 (26 Ga) thick, 1/4 H temper, or equivalent UNS No.
C17200, (ASTM temper TD01) heat treated 2 hours @ 600 degrees
fahrenheit (ASTM TH01), R/C 38-43. As an example not intended to be
limiting, the contacts 33A may have an overall height in FIG. 14 of
about 0.17 inches, a overall length (FIG. 13) of about 1.44 inches
and an overall width of approximately 0.32 inches.
FIGS. 22 and 23 illustrate another embodiment of battery contact
33B for use with a drive assembly having the battery terminals of
FIG. 11. The battery contact 33B is similar to the battery contact
33A except in that the contact 33B has a slightly different shape
when viewed in the top view.
The handle portion 6 of the housing has a releasable attachment
means for releasably attaching the battery 30 to the battery
receiving portion 48 in a direction other than the direction of
elongation of the handle portion 6. In the illustrated embodiment,
that means comprises surfaces on the battery receiving portion 48
defining track portions 49 with flanges that are elongate in a
direction substantially parallel to the longitudinal axis D of the
drive portion. The battery 30 has a pair of opposite mounting
grooves 35 adapted to cooperably receive the flanges of the track
portions 49 (see FIGS. 4 and 6).
The battery pack 30 also has a pair of flexible, resilient
cantilever members 37 having opposite ends. Each of the cantilever
members 37 has a first end attached to the battery housing 31 and
an enlarged distal end 38. The cantilever members 37 project from
the structure defining the grooves 35 in a direction other than
direction of elongation of the handle portion 6 (preferably in a
direction substantially parallel with the top of the battery and
the drive portion axis D). Referring now to FIG. 11, the battery
receiving portion 48 of the housing includes a cantilever member
receiving cavity 77 formed in part by a relatively thin shelf. The
cantilever member receiving cavity 77 includes radiused side walls
75 (see FIG. 12).
The flexible, resilient cantilever members 37 are shown mounted in
the cantilever member receiving cavity 77 in FIG. 12. When the
battery 30 is mounted on the battery receiving portion 48, the
flexible, resilient cantilever members 37 interfere with the
surfaces defining the cantilever member receiving cavity 77 to
resist movement of the battery 30 relative to the rest of the
device 10, particularly movement in the D axis direction. The
flanges of the track 49 cooperably engage the grooves 35 and
prevent the battery 30 from separating from the rest of the device
10.
The distal ends 38 of the flexible, resilient cantilever members 37
have a bevel 78 to allow them to ramp onto the shelf forming the
cavity 77. The engagement between the bevel 78 and the shelf
forming the cavity 77 forces the flexible, resilient cantilever
members 37 upwards in the H axis direction (in FIG. 2) when the
battery 30 is mounted in the battery receiving portion 48.
Consequently, the battery 30 is forced into abutment with the
manually grasping portion 5. When the battery 30 is fully mounted
in the battery receiving portion 48: (1) portion 71 (see FIG. 3) of
the battery housing 31 is preferably in contact with the bottom
side of the shelf forming the cavity 77, and (2) the flexible,
resilient cantilever members 37 are in engagement with the side
surfaces forming the cavity 77 which results in a pinching
interference fit that tends to resist transmission of vibration to
the contacts 33 or 33A. The pinching interference holds the flanges
of the track portions 49 in engagement with the grooves 35 of the
battery housing 31 to retain the battery 30 attached to the
handgrip 5.
The enlarged distal ends 38 of the flexible, resilient cantilever
members 37 have an outward biased radius 28. When the battery 30 is
inserted into the receiving portion 48 of the handle portion 6, the
outward biased radius 28 contacts the radiused side wall 75 (FIG.
12). The width between the outermost portions of the two distal end
outward biased radiuses 28 is greater than the width of the
radiused side walls 75. With this difference in widths, the
flexible, resilient cantilever members 37 are forced inward when
the battery 30 is received in the battery receiving portion 48
thereby generating a resistance to movement. For example, the
interference is preferably less than about 0.1 inches and is more
preferably less than about 0.02 inches. This slight interference
causes the resilient members 37 to deflect and to provide excellent
frictional contact with the cavity 77 in the battery receiving
portion 48. In the manner described above, the cantilever members
37 stabilize the front end of the battery 30. This is especially
effective in resisting movement when using the instrument is used
for oscillating sawing where side to side forces (perpendicular to
the axis H) are generated.
Preferably, the flexible, resilient cantilever members 37 comprise
a single, unitary, integral monolithic piece with the battery
housing 31. Thus, the material for the battery housing 31 should be
sufficiently durable for forming a battery housing (e.g. it should
be able to withstand autoclaving procedures), and yet resilient
flexible to accomplish the repeated interference fit of the
flexible, resilient cantilever members 37 and cavity 77. Any
suitable materials may be used including the materials discussed
above as suitable for use to construct the casing 31.
Alternatively, the flexible, resilient cantilever members 37 may be
constructed from a material different than the material used to
construct the casing 31.
When the drive assembly 10 is held in the position referenced in
FIG. 2, the mounting grooves 35 and flanges of the track portions
49 are cooperable to resist the effect of gravity on the device 10
which, in prior art devices, tends to urge the battery away from
contact with the rest of the device. A latch 56 is provided for
releasably securing the battery 30 to the battery receiving portion
48, and for retaining the electrical contact between contacts 33 of
the battery 30 and the battery terminals 39 (or the terminals 39A
with the contacts 33A) of the battery receiving portion 48. The
latch 56 comprises a blocking member 57 mounted on the lower
portion of the housing 6 for movement between a latched (FIG. 4)
and a release position. A coil spring 58 biases the blocking member
57 toward the latched position. The latch 56 also includes the
battery housing 31 having surfaces defining slot 34 for receiving a
chamfered end 55 of the blocking member 57.
In the latched position, (1) the mounting grooves 35 of the battery
30 are received in the track portions 49 (see FIG. 4) in the
battery receiving portion 48, and (2) the chamfered end 55 of the
blocking member 57 is biased into engagement with the slot 34 of
the battery 30 to lock the battery 30 to the battery receiving
portion 48 of the housing. Indicia 59 may be present to provide
user information such as how to unlatch the battery 30.
The latch 56 also includes means for automatically moving the
blocking member 57 from the latched toward the release position as
the battery 30 is mounted to the battery receiving portion 48. That
means comprises the battery housing 31 having a ramp surface 36
adapted to engage the chamfered end 55 on the blocking member
57.
Referring to FIG. 2, as the battery 30 is slid into the track
portions 49 of the battery receiving portion 48, the ramp surface
36 engages the chamfered end 55 of the blocking member 57 and cams
the blocking member 57 toward the release position, thereby
enabling the flanges of the track portions 49 to be slid into the
corresponding, cooperable grooves 35 of the battery housing 31.
Once the battery 30 is fully mounted on the battery receiving
portion 48, the chamfered end 55 of the blocking member 57 is
biased into engagement with the slot 34 of the battery housing 31
as described above. The side of the blocking member 57 opposite
chamfered end 55 is not chamfered to resist inadvertent release of
the battery 30.
As a portion of the electrical circuit means mentioned above, the
drive assembly 10 also includes a convenient rotary switch means,
operated by ribbed member 72 on the proximal end 1 of the drive
housing 4 opposite drive member 18, for causing the motor 12 to
rotate the drive member 18 either in forward or reverse (clockwise
or counterclockwise) directions, or to prevent any rotation by the
motor 12 even when the trigger 40 is moved to its inner position.
Indicia 73 indicate when the device is in the forward, reverse or
stop modes.
FIG. 21 is a schematic illustration of the switch means. The motor
control switch with forward, off and reverse positions is
preferably mounted behind the motor. The motor control switch
includes a rotatable knob 72 with an attached magnet 62 and a
detent mechanism 63 with three positions that correspond to the
forward, off and reverse positions. When the knob is rotated fully
clockwise, the magnet 62 by its magnetic field, activates one of
two hall sensors 61 to run the motor counter-clockwise when facing
the output shaft. When the knob is rotated fully counter-clockwise,
it will reverse the motor. A center, neutral (off) position is also
included.
The present invention has now been described with reference to
several embodiments thereof. It will be apparent to those skilled
in the art that many changes or additions can be made in the
embodiments described without departing from the scope of the
present invention. Thus, the scope of the present invention should
not be limited to the structures described in this application, but
only by structures described by the language of the claims and the
equivalents of those structures.
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